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Fuel Tank: Installation

  1. Connect the fuel delivery tube to the fuel pump and install it to the clamp. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE D) .
    G16523404Courtesy of SUBARU OF AMERICA, INC.
  2. Support the fuel tank with a transmission jack, set the fuel tank in place, and temporarily tighten the bolts of the fuel tank band.
    CAUTION: A helper is required to perform this work.
    G16523403Courtesy of SUBARU OF AMERICA, INC.
  3. Tighten the bolts of the fuel tank band in the numerical order shown in the figure.

    Tightening torque: 

    33 N.m (3.4 kgf-m, 24.3 ft-lb)

    Fig 1: Fuel Tank Band Bolts Tightening Sequence
    G16523407Courtesy of SUBARU OF AMERICA, INC.
  4. Connect the fuel delivery tube (B) and fuel delivery tube (A) to the fuel pipe assembly. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE E) .
    G16523402Courtesy of SUBARU OF AMERICA, INC.
  5. Connect the vent tube (C), circulate tube (B) and fuel filler hose (A).

    Vent tube: 

    Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE H) .

    Circulate tube: 

    Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>QUICK CONNECTOR CONNECTION (TYPE D) .

    Fuel filler hose: 

    Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL DELIVERY AND EVAPORATION LINES>INSTALLATION>FUEL FILLER HOSE CONNECTION .

    G16523401Courtesy of SUBARU OF AMERICA, INC.
  6. Install the rear suspension assembly. Ref. to REAR SUSPENSION>SUB FRAME>INSTALLATION .
  7. Install the fuel tank protector. Ref. to FUEL INJECTION (FUEL SYSTEMS) (H4DO)>FUEL TANK PROTECTOR>INSTALLATION .
  8. Lower the vehicle.
  9. Set the harness on the service hole cover RH and connect the connector to the fuel sub level sensor.
    CAUTION: Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel sub level sensor and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.
    G16523400Courtesy of SUBARU OF AMERICA, INC.
  10. Install the service hole cover RH of fuel sub level sensor.
    1. Apply new butyl tape as shown in the figure.
      NOTE:
      • Before applying butyl tape, degrease the attaching surface of the service hole cover.
      • Apply butyl tape within the range A.
      • Apply butyl tape seamlessly along the attachment guide on the service hole cover.
      • Apply butyl tape so that the start and the end of application overlap within the range B shown in the figure.

      Preparation items: 

      Butyl tape: 3M Butyl Tape 8626 or equivalent

      G16523411Courtesy of SUBARU OF AMERICA, INC.
      (A) Butyl tape
      (B) Application guide
      (C) Range A
      (D) Range B
    2. Set the service hole cover RH to the position shown in the figure.
      NOTE: Before setting the service hole cover, degrease the attaching surface of the floor.
      G16523412Courtesy of SUBARU OF AMERICA, INC.
      (A) Corner bead on the floor and flange of the service hole cover
      (B) Floor protrusion and cutout on the service hole cover
    3. Install the service hole cover RH to the floor as shown in the figure.
      NOTE: Press hard the entire perimeter of the butyl tape attachment area on the service hole cover for secure adhesion.
      G16523413Courtesy of SUBARU OF AMERICA, INC.
      (A) Align the height of the flange of the service hole cover with the height of the corner bead on the floor.
      (B) Closely attach the flange of the service hole cover to the floor.
    4. Install the grommet to the service hole cover RH.
    G16523398Courtesy of SUBARU OF AMERICA, INC.
  11. Connect the connector to the fuel pump.
    CAUTION: Before connecting, make sure that there are no foreign matters, water, etc. inside the connectors of fuel pump and harness. If any foreign matters, water, etc. are found, remove them with air blow and connect the connector after it has dried completely.
    G16523397Courtesy of SUBARU OF AMERICA, INC.
  12. Install the service hole cover LH of fuel pump.
    1. Apply new butyl tape as shown in the figure.
      NOTE:
      • Before applying butyl tape, degrease the attaching surface of the service hole cover.
      • Apply butyl tape within the range A.
      • Apply butyl tape seamlessly along the attachment guide on the service hole cover.
      • Apply butyl tape so that the start and the end of application overlap within the range B shown in the figure.

      Preparation items: 

      Butyl tape: 3M Butyl Tape 8626 or equivalent

      G16523416Courtesy of SUBARU OF AMERICA, INC.
      (A) Butyl tape
      (B) Application guide
      (C) Range A
      (D) Range B
    2. Set the service hole cover LH to the position shown in the figure.
      NOTE: Before setting the service hole cover, degrease the attaching surface of the floor.
      G16523417Courtesy of SUBARU OF AMERICA, INC.
      (A) Corner bead on the floor and flange of the service hole cover
      (B) Floor protrusion and cutout on the service hole cover
    3. Install the service hole cover LH to the floor as shown in the figure.
      NOTE: Press hard the entire perimeter of the butyl tape attachment area on the service hole cover for secure adhesion.
      G16523418Courtesy of SUBARU OF AMERICA, INC.
      (A) Align the height of the flange of the service hole cover with the height of the corner bead on the floor.
      (B) Closely attach the flange of the service hole cover to the floor.
    4. Install the grommet to the service hole cover LH.
    G16523395Courtesy of SUBARU OF AMERICA, INC.
  13. Install the cushion assembly rear seat RH and the cushion assembly rear seat LH. Ref. to SEATS>REAR SEAT>INSTALLATION .
  14. Connect the ground terminal to battery sensor. Ref. to REPAIR CONTENTS>NOTE>BATTERY .
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